Cable connector with crimping die locating grooves



Sept. 27, 1956 FLYNN ET AL 3,275,738

CABLE CONNECTOR WITH CRIMPING DIE LOCATING GROOVES Filed April 50, 1964 2 Sheets-Sheet l Sept. 27, 1966 FLYNN ET AL 3,275,738

CABLE CONNECTOR WITH CRIMPING DIE LOCATING GROOVES Filed April 50, 1964 2 Sheets-Sheet i.

United States Patent 3,275,738 CABLE CONNECTDR WITH CRIMPING DIE LOCATING GROOVES Gordon L. Flynn, Trussville, and Benjamin E. Kidd III, and Vernon E. Peek, Birmingham, Ala., assignors to Anderson Electric Corporation, Leeds, Ala, a corporation of Alabama Filed Apr. 30, 1964, Ser. No. 363,932 9 Claims. (Cl. 174-94) This invent-ion relates to cable connectors, and more particularly to a cable connector especially adapted to be crimped about a cable along the length thereof.

Among the several objects of this invention may be noted the provision of a cable connector which will permit connecting a branch or tap conductor or cable to a main conductor or cable intermediate the ends of the latter; the provision of a connector of the class described which is formed of a malleable material for crimping by dies of a 4-way compression crimping tool to securely connect a branch cable to a main cable; the provision of a parallel tap connector which is formed as an extrusion, thereby reducing the cost of manufacture; the provision of a connector which limits and controls deformation of areas of the connector by the crimping tool; the provision of a connector which can be formed of a material which is bendable although not necessarily readily deformable; the provision of a connector for cables or the like wherein compression of the connector by a crimping tool does not tend to unseat a cable in the connector; the provision of a connector adapted to be compressed by a crimping tool wherein separation of the strands of stranded cable is minimized; and the provision of a connector of the class described which may be of any one of various lengths, depending upon certain requirements of the connector to be made. Other objects and features will be in part apparent and in part pointed out hereinafter.

The invention accordingly comprises the constructions hereinafter described, the scope of the invention being indicated in the following claims.

In the accompanying drawings, in which several of various possible embodiments of the invention are illustrated,

FIG. 1 is a perspective view of a connector of this invention;

FIG. 2 is an end elevation, showing a portion of the head of a crimping tool employed to crimp the connector and showing, in section, a tap or branch cable extending through the connector;

FIG. 3 is an end elevation similar to FIG. 2, showing an intermediate stage in the method of connecting a branch cable to a main-line cable;

FIG. 4 is an end elevation of the connector after crimping, showing the cables joined by the connect-or in cross section;

FIG. 5 is a side elevation taken from the right-hand side of FIG. 4;

FIG. 6 is a side elevation taken from the left-hand side of FIG. 4;

FIG. 7 is a perspective view of another connector of this invention;

FIG. 8 is an end elevation of the connector of FIG. 7 initially gripped by the dies of a crimping tool and showing the main and tap caiblcs in the connector;

FIG. 9 is a partial perspective view taken on line 99 of FIG. 10 and showing the connector of FIGS. 7 and 8 after crimping by the tool;

FIG. 10 is a side elevation of the crimped connector of FIG. 9;

FIG. 11 is a perspective view of another connector of this invention; and

FIG. 12 is a perspective view, partially in cross section, showing a portion of the connector of FIG. 11 after being crimped.

Corresponding reference characters indicate correspon=ding parts throughout the several views of the draw- Referring now more particularly to the drawings, a cable connector of this invention is indicated generally at reference numeral 1. This connector includes a body portion 3 and a jaw portion 5 extending from one edge of the body portion. Body and jaw portions 3 and 5 are integrally formed of any suitable malleable material, such as aluminum or aluminum alloys, which may be crimped by compression crimping tools such as for example the type disclosed in copending application Serial No. 115,625, filed June 8, 1961, now Patent No. 3,154,- 981. Where the connector is to be used to join electrical conductors or cables, it is formed of a metallic material that is not only malleable, but also has high electrical conductivity. The connector 1 may be molded or forged, but is preferably extruded and cut into any of various desired lengths for a purpose to be made apparent hereinafter.

law and body portions 5 and 3 are formed so as to produce a relatively deep channel 7 extending in an axial direction throughout the length of the connector. The bottom of channel 7 provides a seat 9 for an intermediate portion of a long length of electrical conductor or cable, such as indicated at C (see FIGS. 3 and 6). Extending through body portion 3 parallel to channel 7 is a passage or bore 11 adapted to receive a branch or tap cable TC.

The outer end of jaw portions 5 is provided with a lip 13 extending in an axial direction throughout the length of the connector. Similarly, body portion 3 is provided with a lip 15 adjacent the lateral opening of channel 7. Lips 13 and 15 are so formed that in combination with the respective adjacent peripheral portions of connector 1 they form grooves 17 and 19, respectively. The shape and size of the connector are such and the grooves 13 and 15 are so located that they are generally positioned on two corners S1 and S2 of a square S (shown in broken lines in FIG. 2). All the corners of square S are located substantially on the periphery of the connector in a transverse plane, i.e., a plane substantially perpendicular to the length of the connector. More particularly, the grooves 17 and 19 are located on the two adjacent corners S1 and S2 of the square which are on opposite sides of the lateral opening of the channel 7. The other two corners of the square S are designated S3 and S4.

Grooves 17 and 19 are engageable by two crimping dies D1 and D2 of a 4-die crimping tool, and also indirectly position or orient two remaining dies D3 and D4 so that they contact the outer peripheral surface of the connector '1 at corners S3 and S4 as illustrated in FIG. \2. The dies D1'D4 are arranged in a rightangle relation to each other with the tips of the dies forming a square (it connected by lines) which may be superimposed on square S.

\It is preferred that the connector have a transverse cross section which is of generally C- or W-shape. It is also desirable that the depth of channel 7 (i.e., the

distance between the opening of channel 7 and its bottom surface, seat 9) be more than one-half the length of the diagonal of the square S. This provides a readily deformable jaw portion which may be deformed around cable C to completely encircle the latter. The wall portion 21 between the side of channel 7 and the bore 11 is relatively thin so as to be readily deformable for being mashed or crimped onto tap cable TC. Wall 21 serves as a separator when cables C and TC are made of unlike metals.

The connector may be loosely suspended from main cable C prior to crimping, if desired, by hooking the jaw over the cable. The wall of channel 7 opposite wall portion 2 1 is curved concavely for receiving the cable C and reducing the possibility of the connector slipping sidewise off cable C. However, in making a tap or branch connection to a main cable, a lineman usually first places the connector in the crimping tool in the position illustrated in FIG. 2 with the dies adjacent either the left or right-hand half of the connector as viewed in FIG. 6. The tool is then operated in a known manner to cause the dies to move in slightly for lightly gripping the connector. The lineman then inserts the end of branch cable TC through bore 11, as illustrated in FIG. 2. When cable TC is in bore 11, it may be bent adjacent the ends of the connector to temporarily hold it in place until the crimping operation is complete. By lifting the tool, the connector with the end of cable TC therein may be raised and hooked over the main cable C, i.e., the connector is manipulated so that cable C moves sidewise or laterally, relative to connector 1, into seat 9 through channel 7. FIG. 3 illustrates this, with jaw portion 5 in position about an intermediate portion of main cable C. The compression tool is actuated by the lineman to move dies D 1-D4 inward relative to one another and to maintain substantially a right-angle or equidistant relationship between adjacent dies, thereby crimping the connector. Actuation of the tool is continued until the cables C and TC are securely gripped by the connector, as shown in FIG. 4. 'If the cables are formed of a malleable material, as shown, they are also deformed until the pres sure exerted by the 4-way compression tool. The dies of the tool are then released and retracted. The connector shown is of sutficient length to have two crimping operations performed thereon. Accordingly, the tool is moved axially along the connector until it is clear of the first crimp, and the same crimping procedure is repeated. It will be understood that the length of the parallel tap connector of this invention may be shorter than shown so as to accommodate a single crimping operation, or it may be considerably longer to permit three or more crimping operations along the length of the connector.

It will be seen that the grooves 17 and 19 and their particular location senve positively to orient connector 1 with respect to the dies vD1-D4 and prevent any 'die from being positioned so as to move directly into the opening of the channel 7. Thus, a branch cable may be quickly and easily positioned and crimp-connected to a main cable. Furthermore, the grooves prevent rotation of the connector in the tool when the connector is initially placed in the tool, and during the crimping operation.

Referring now to FIGS. 7-10, another cable connector of this invention is indicated generally at 23 and is somewhat similar to the connector previously described, like reference numerals being used to indicate the same or similar parts. The connector 23 can be formed from any suitable material, including copper, aluminum and alloys thereof and connector 23 may be crimped by suitable compression crimping tools such as the type shown in the copending patent application referred to above. The connector 23 not only has the grooves 17 and 19 previously described positioned at corners S1 and S2, respectively, of the square S shown in the broken lines in FIG. 8, but additionally has a groove 25 po- 7 sitioned on the outer surface or periphery of the connector and extending longitudinally therealong. Groove '25 is located in jaw portion 5 substantially at the juncture of the body portion 3 and jaw portion 5 of the connector. The bottom of groove 25 is spaced from but adjacent corner S4 of square S and is between corners S3 and S4 of the square S. Groove 25 has a substantially flat side 26 located relative to corner S4 of square S so that the side 26 is engaged by the end of die D4 during initial engagement between the dies and the connector. The side 26 of groove 25 is formed in the periphery of connector 23 so that it is substantially coplanar with or parallel to a side of die D4 during initial engagement between die D4- and groove 25 as shown in FIG. 8. The edge of die D4 of the compression crimping tool initially engages the upper edge of side 26 of groove '25 and is slightly out of alignment with the bottom of the groove upon initial gripping contact of dies D1-D4 on the connector periphery.

The groove 25 permits the die D4 of the crimping tool to slide freely along groove side 26 without compressing the connector 23 during the initial operation of the crimping tool from the position shown in FIG. 8. After this initial sliding movement, the die D4 will bottom in the groove 25 and start indenting or compressing the connector. This sliding movement reduces the possibility of the die D4 pushing the main conductor or cable C out of the seat 9 of channel 7 and toward die D l during initial movement of the crimping tool dies. By limiting movement of cable C during initial movement of the tool dies, there is less chance that the strands of cable C will be separated before jaw portion 5 is closed. At the time crimping die D4 stops sliding and starts its crimping action, die D1 has moved lip 13 downwardly as viewed in FIG. 8 so as to partially encompass cable C and prevent strand separation and movement of cable C out of its seat 9.

An arm or jaw portion 27 is provided in connector 23 and projects from an edge of body portion 3 opposite jaw portion 5. A deep recess 29 is defined by jaw portion 27 and wall 21 and this recess 29 is located between lip 15 and bore 11 and opens laterally of the connector. The Wall 21 separates the recess 29 and the bore 11.

The jaw portion 27 and jaw portion 5 together define a lateral opening or mouth to receive the main cable C with lips 13 and 15 being at the outer edges or margins of the mouth. The recess 29 permits the connector jaw portions 5 and 27 to be moved by bending or deforming to the desired closed position by the crimping tool. When viewed from the end (FIG. 8) the connector 23 is generally C- or W-shaped.

During operation of the compression tool in the manner previously described, the jaw portion 5 and lip 13 are moved toward wall 21 until lip 13 is in engagement with the wall as shown in FIG. 9, and simultaneously jaw portion 27 is moved inwardly across recess 29 to a position against wall 21. Jaw portions 5 and 27 are dimensioned so that lip 15 overlaps the edge of lip 13 when the crimping operation is complete. The formation of the recess 29 and provision of jaw portion 27 facilitates closing up of the connector during crimping operation. The size of jaw 5 may be shortened or extended to achieve the desired overlap or relation between lips 13 and 15. Here, as in other embodiments of the invention, the crimping tool may be operated one or more times at spaced intervals along the connector, depending upon the length of the connector, etc. FIG. 10 shows three spaced crimps in the connector 23.

The connector 23 requires less deformation of the metal of the connector than does connector 1, and as a result the connector 23 can be made of materials which deform very little but which will bend under pressure. Thus, copper and copper alloys can he used in making the connector 23. Of course, readily deformable metals, such as aluminum and aluminum alloys, can also be used for making the connector 23. In this regard, it will be noted that provision of the groove 25 and its location relative to die D4 reduce the need to deform a large body of the metal as in jaw portion 5 or body portion 3 in the connector 1 shown in FIGS. 1-6.

Another connector embodiment of this invention is indicated generally at 31 in FIGS. 11 and 12 and is some what similar to the connector 23, and like reference numerals have been used to designate the same or similar parts. Connector 31 has a projection or ridge 33 running longitudinally or axially along the inner surface of arm or jaw portion 27 between lip 15 and wall 21 and the projection or ridge 33 is somewhat pointed and extends into recess 29 toward wall 21 or channel 7. The projection or ridge 33 is substantially opposite groove 19 and crimping die D2 when the connector 31 is mounted in a tool of the type previously described. The die D2 causes projection 33 to be moved toward wall 21 and channel 7 until the projection 33 engages wall 21 and is deformed against the Wall 21. Projection 33 is of a size and located so that, when the connector is crimped as shown in FIG. 12, the projection 33 is substantially at the mouth or outer end of the channel 7 and opposes any tendency of cable C or strands of the cable to move out of channel 7. During crimping operations, projection 33 and lip 15 provide a wall against which lip 13 is moved and the lips 13 and 15 in the deformed connector are in abutting engagement and project outwardly from the connector as illustrated in FIG. 12. This movement and resulting deformation of the material from which the connector is made is somewhat greater than that required for the connector 23 and, for this reason, it is normally desirable to make connector 31 of a material which is readily deformable during crimping operations. Aluminum and aluminum alloys are preferably used in making connector 31.

When using any of the connectors of this invention, a sealant or antioxidant material (not shown) may be placed in the cable-receiving portions of the connectors or applied to the cable surfaces to be crimp-connected and the sealant will be dispersed around the cables and between the strands of the cables during crimping of the connectors.

In View of the above, it Will be seen that the several objects of the inventoin are achieved and other advantageous results attained.

As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

What is claimed is:

1. A connector for interconnecting a pair of cables comprising a main body portion and a jaw portion extending from one edge of the body portion and forming a relatively deep channel opening laterally of the connector, said main body and jaw portions being integrally formed of a malleable metal in a generally C-shaped configuration in transverse cross section, said channel extending in an axial direction throughout the length of said connector for receiving one of said cables, a bore in said body portion extending parallel to said channel through out the length of said connector for receiving the other of said cables, said connector having a pair of die-receiving grooves in its periphery located on opposite sides of the lateral opening of said channel and extending in an axiav direction throughout the length of the connector for orienting two dies of a four-die crimping tool, said grooves being generally located on two corners of a square all the corners of which are substantially located on the periphery of the connector in a plane substantially perpendicular to the axis of the connector, and a wall between said channel and said bore which is of such a thickness that it is readily deformable under the pressure of said dies necessary to effect crimp connection.

2. A connector as set forth in claim 1 including first and second lips extending inan axial direction throughout the length of the connector, said first lip being located on the outer end of said jaw adjacent one of the corners of the square, said second lip being located on said body portion adjacent the lateral opening of said channel and a second corner of the square, said lips and the respective adjacent peripheral portions of the connector forming said pair of grooves on adjacent corners of the square.

3. A connector as set forth in claim 1 wherein said channel is curved at its bottom to provide a seat for said one cable, said grooves being located on two adjacent corners of the square and adjacent the lateral opening of said channel and said bore.

4. A connector as set forth in claim 1 wherein said channel has a depth of more than one-half the length of the diagonal of the square.

5. A connector as set forth in claim 1 having a second jaw portion extending from said body portion in spaced relation to the first-named body portion, said pair of grooves being located on outer surfaces of said jaw portions.

6. A connector as set forth in claim 5 having a projection on one of said jaw portions extending inwardly from the jaw portion and generally toward said body portion and said channel.

7. A connector for interconnecting a pair of cables comprising a main body portion and two spaced jaw portions, one of said jaw portions extending from one edge of the body portion and forming a relatively deep channel opening laterally of the connector, the other of said jaw portions extending from another edge of the body portion and forming a recess extending throughout the length of the connector, said main body and jaw portions being formed of a malleable metal, said channel extending in an axial direction throughout the length of said connector for receiving one of said cables, a bore in said body portion extending parallel to said channel throughout the length of said connector for receiving the other of said cables, said connector having three die-receiving grooves in its periphery extending in an axial direction throughout the length of the connector .for receiving dies of four-die crimping tool, a pair of said grooves being generally located in said jaw portions on two adjacent corners of a square all the corners of which are substantially located on the periphery of the connector in a plane substantially perpendicular to the axis of the connector and orienting two dies of the crimping tool, the bottom of the third of said grooves being spaced from but adjacent a third corner of the square.

8. A connect-or as set forth in claim 7 wherein each of said jaw portions has a lip at the outer end thereof and said jaw portions are dimensioned relative to each other and to the body portion to be bent to a position with the lips of said jaw portions overlapping to thereby close said channel and retain said one of said cables therein.

9. A connector as set forth in claim 7 wherein said third groove has a side located relative to the third corner of the square to be engaged by one of the dies of the crimping tool during initial contact between the dies and the connector whereby said one of said dies has a sliding contact with said side during initial crimping operations.

References Cited by the Examiner UNITED STATES PATENTS 2,229,758 l/ 1941 Metcal'f. 2,884,478 4/ 1959 Becker et a1 l74--94 2,938,069 5/1960 Tocd-tman et a1. 17471 X 3,022,370 2/1962 Osborn l7471 3,185,762 5/1965 Shaw l7484 X LEWIS H. MYERS, Primary Examiner.

DARRELL L. CLAY, Examiner. 

1. A CONNECTOR FOR INTERCONNECTING A PAIR OF CABLES COMPRISING A MAIN BODY PORTION AND A JAW PORTION EXTENDING FROM ONE EDGE TO THE BODY PORTION AND FORMING A RELATIVELY DEEP CHANNEL OPENING LATERALLY OF THE CONNECTOR, SAID MAIN BODY AND JAW PORTIONS BEING INTEGRALLY FORMED OF A MALLEABLE METAL IN GENERALLY C-SHAPED CONFIGURATION IN TRANSVERSE CROSS SECTION, SAID CHANNEL EXTENDING IN AN AXIAL DIRECTION THROUGHOUT THE LENGTH OF SAID CONNECTOR FOR RECEIVING ONE OF SAID CABLES, A BORE IN SAID BODY PORTION EXTENDING PARALLEL TO SAID CHANNEL THROUGHOUT THE LENGTH OF SAID CONNECTOR FROM RECEIVING THE OTHER OF SAID CABLES, SAID CONNECTOR HAVING A PAIR OF DIE-RECEIVING GROOVES IN ITS PERIPHERY LOCATED ON OPPOSITE SIDES OF THE LATERAL OPENING OF SAID CHANNEL AND EXTENDING IN AN AXIAL DIRECTION THROUGHOUT THE LENGTH OF THE CONNECTOR FOR ORIENTING TWO DIES OF FOUR-DIE CRIMPING TOOL, SAID GROOVES BEING GENERALLY LOCATED TO TWO CORNERS OF A SQUARE ALL THE CORNERS OF WHICH ARE SUBSTANTIALLY LOCATED ON THE PERIPHERY OF THE CONNECTOR IN A PLATE SUBSTANTIALLY PERPENDICULAR TO THE AXIS OF THE CONNECTOR, AND A WALL BETWEEN SAID CHANNEL AND SAID BORE WHICH IS OF SUCH A THICKNESS THAT IT IS READILY DEFORMABLE UNDER THE PRESSURE OF SAID DIES NECESSARY TO EFFECT CRIMP CONNECTION. 